1998 Ford Windstar problems

What is wrong

Ford Motor Company (Ford) is recalling certain model year 1998-2003 Windstar vehicles manufactured September 2, 1997, to July 3, 2003. The affected vehicles were previously remedied to safeguard against the rear axle cracking from corrosion, however, the remedy brackets may have been misinstalled. The incorrect bracket installations may limit the effectiveness of the service repair for the federal safety agency recalls 10V‑385, 12V‑193, and 12V‑195.

Risk

If the brackets were not installed properly, the rear axle may fracture, affecting the vehicle handling and increasing the risk of a crash.

Remedy

Ford will notify owners, and dealers will inspect the brackets to verify their proper installation. If a bracket is found to have been misinstalled, the rear axle will be replaced. These repairs will be performed free of charge. The began on October 21, 2015. Owners may contact Ford customer service at 1‑866‑436‑7332. Ford's number for this recall is 15S27.

Recall number 15V608000 · Recall details

What is wrong

Ford is recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997, through july 3, 2003, and currently registered or originally sold in virginia. Over time, corrosion can weaken the rear axle making it susceptible to torsional stress. Corrosion and stress can lead to cracks which, if undetected, can increase and result in a complete fracture of the axle.

Risk

A fractured axle can affect vehicle handling and increase the risk of a crash.

Remedy

Ford will notify owners, and dealers will inspect and install rear axle reinforcement brackets, or replace the axles, as necessary. This service will be performed free of charge. The recall began on june 19, 2012. Owners may contact ford at 1‑866‑436‑7332.

Recall number 12V193000 · Recall details

What is wrong

Ford is recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997, through july 3, 2003, registered in puerto rico. Due to increased stresses caused by high cycles of torsional loading, specific to this market, the rear axle can crack.

Risk

A fractured axle may result in a loss of vehicle control, increasing the risk of a crash.

Remedy

Ford will notify owners, and dealers will inspect and install a reinforcement bracket on the rear axle or replace the axles, as necessary. This service will be provided free of charge. The recall began on june 1, 2012. Owners may contact the ford motor company customer relationship center at 1‑866‑436‑7332.

Recall number 12V195000 · Recall details

What is wrong

Ford is recalling certain model year 1998-2003 windstar vehicles manufactured from september 1, 1997 through february 28, 2003 and currently registered or originally sold in connecticut, delaware, district of columbia, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, and wisconsin. After many years of vehicle service in these areas, corrosion can weaken the rear axle, making it susceptible to torsional stress. Corrosion and stress can lead to cracks which if undetected can propagate and result in a complete fracture of the axle.

Risk

A fractured axle can affect vehicle handling and increase the risk of a crash.

Remedy

As parts become available, dealers will inspect and if necessary install the rear axle reinforcement brackets free of charge. This service will be performed free of charge. The safety recall began on october 20, 2010. Owners may contact ford at 1‑866‑436‑7332.

Recall number 10V385000 · Recall details

What is wrong

Ford is recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 f-250 sd through f-550 sd diesel, 1992-2003 e-150 through e-550, 1995-2002 explorer, 1997 and 2002 mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 f53 vehicles equipped with the texas instruments speed control deactivation switch (scds). The scds may leak internally and then overheat, smoke, or burn.

Risk

A vehicle fire could occur with or without the engine running.

Remedy

Ford will notify owners that dealers will install a fused wiring harness in line with the scds. On 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair as necessary. Repairs will be completed free of charge. The safety recall began on october 27, 2009. Owners may contact ford at 1‑888‑222‑2751.

Recall number 09V399000 · Recall details

What is wrong

On certain minivans originally sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, and wisconsin, and in the district of columbia. The front coil springs could fracture as a result of corrosion. Depending on the location of the fracture, a broken spring could move past the spring seat and contact a front tire.

Risk

Some tires have deflated due to contact with a broken spring.

Remedy

Dealers will install protective shields around the front coil springs. Owner notification began september 6, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1‑800‑392‑3673.

Recall number 01V199000 · Recall details

What is wrong

Vehicle description: mini vans, light pickup trucks, and sport utility vehicles. Off lease canadian vehicles equipped with daytime running lights which meet canadian requirements and not the photometric requirements of fmvss 108, "lamps, reflective devices, and associated equipment." according to ford, the vehicles were imported into the u.s. Erroneously.

Risk

The light given off from the daytime running lights is brighter than allowed by u.s. Standards.

Remedy

Dealers will be advised to deactivate the running light function and to complete any outstanding safety recalls on these vehicles.

Recall number 00V168000 · Recall details

What is wrong

Vehicle description: minivans. The brake fluid master cylinder is recessed and oriented in the engine compartment so that the brake fluid warning statement embossed on both the top of the filler cap and the side of the reservoir body are not entirely visible by direct view. These vehicles may not fully comply with requirements of fmvss no. 135, "passenger car brake systems."

Remedy

Owners will be provided with new labels and installation instructions.

Recall number 99V147000 · Recall details

What is wrong

Vehicle description: passenger vehicles and mini-vans. The rack and pinion steering gears may have damaged input shaft bearings.

Risk

This condition can increase steering efforts, affecting steering control.

Remedy

Dealers will inspect the date code on the rack and pinion steering gear, and, if necessary, replace those rack and pinion assemblies that fall within the suspect date code range. The date codes for windstar model vehicles are 97jb09 or 97jc08; the date codes for mustang model vehicles are 97j09b or 97j08b.

Recall number 97V165000 · Recall details

What is wrong

Vehicle description: passenger vehicles equipped with ax4s automatic transaxles. The low/intermediate servo cover can separate from the transaxle while the vehicle is being driven. If this occurs, transmission fluid will leak contacting the catalytic converter.

Risk

The catalytic converter temperature may be hot enough to ignite the transmission fluid and cause a vehicle fire.

Remedy

Dealers will inspect the transmission and replace these servo covers.

Recall number 97V097000 · Recall details

What is wrong

Vehicle description: minivan equipped with second row bench seats with optional integrated child seat (ics). The headrest lockout mechanism on the seats may not engage and lock the headrests in the "down" position, as intended, when the ics is deployed. A vehicle occupant could move the headrest to the "up" position.

Risk

As a result of the headrest being in the "up" position, a child seated in the ics would receive less than the intended protection in the child head area in the event of a crash.

Remedy

The second row bench seats have been replaced with seats built with revised headrest lockout mechanisms.

Recall number 97V051000 · Recall details

In a letter dated August 26, 2010, Ford Motor Company (Ford) submitted a Defect Information Report notifying the federal safety agency that it will conduct a safety recall (the federal safety agency Recall No. 10V‑385) to address a rear axle defect in model year (MY) 1998 through 2003 Ford Windstar vehicles built at the Oakville assembly plant from September 1, 1997 through February 28, 2003 and either sold or currently registered in high corrosion (Salt-Belt) states where the use of salt and other corrosive chemicals may be used to treat snow/ice covered roads.The following states are included in Ford's recall:Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia and Wisconsin. The subject vehicles utilize a Stamped/Formed axle assembly manufactured by Benteler automotive Corporation of Galesburg, MI.According to Ford, after many years of vehicle service in the Salt-Belt states, corrosion can weaken the rear axle, making it susceptible to torsional stress.There is a risk that the combined effects of corrosion and stress can lead to cracks which, if undetected, can propagate and result in a complete fracture of the axle.A completely fractured axle can affect vehicle handling and increase the risk of a crash.To correct the safety defect, Ford will initially inspect all of the subject vehicles brought into Ford/Lincoln-Mercury dealerships for possible cracked axles.Owners of vehicles without cracked axles will be notified when to return for the installation of reinforcement brackets to extend the axle durability in the presence of corrosion.Owners who have vehicles with cracked axles will either be offered a repair or alternative transportation until parts become available. On May 13, 2010, the Office of Defects Investigation (ODI) opened PE10-016 to investigate complaints of rear axle cracking in MY 1999 through 2003 Ford Windstar minivans.Combining ODI and Ford complaint data, ODI is aware of a total 891 complaints alleging rear axle cracking in the subject vehicles.Over a third of the complaints (334) allege that the cracking progressed to a complete fracture of the rear axle, including 8 allegations of crashes resulting in 3 injuries. Approximately 57 percent of the subject vehicles (524,661) were sold in Salt-Belt states covered by Ford's recall and Ford estimates that approximately 463,000 of these remain in service.Ninety-six percent of the complaints (858) and all of the complaints alleging complete fracture were from the recall region.The action taken by Ford is sufficient to resolve the issues raised by this investigation.Accordingly, this investigation is closed.

PE10016

Ea08-021 is closed with ford's actions in recall 09v‑399 recalling approximately 4.5 million vehicles equipped with texas instruments speed control deactivation switches (scds).with this recall ford has now recalled all of the approximate 16 million ford model vehicles that were manufactured from my 1992 through 2003 with a texas instruments scds.the federal safety agency will continue to monitor the recalled vehicles to ensure remedies installed by ford tomitigate the potential for scds related fires are effective.the agency reserves the right to take further action if warranted by the circumstances.see attached closing report for further details.

EA08021

Odi has received 134 consumer complaints, 285 manufacturer complaints, and 137 manufacturer warranty claims alleging incidents of engine compartment fire in model year (my) 1995 thru 2003 ford windstar vehicles.two of the odi complaints allege the fires caused structural damage to the complainant's home.of the 134 odi complaints, 36 allege the fire occurred while the vehicle was parked, 72 allege the fire occurred while the vehicle was running and 26 of the complaints do not specify if the vehicle was running or not.further review of the odi complaints shows that 72 allege that the speed control deactivation switch (scds) caused the fire and 10 allege that the scds leaked brake fluid on to the ABS module resulting in the fire.there were 52 that did not identify a cause or that identified miscellaneous other causes.odi has also received 89 complaints ( not counted in this resume) alleging that the scds developed a brake fluid leak.thirteen of these complaints say that the leak at the scds resulted in braked fluid reaching the ABS module.this pe has been upgraded to an engineering analysis (ea) to further evaluate the cause of the fires and assess the scope, frequency, and safety consequences of the alleged defect.

PE08035

The subject vehicles range in age from 4?7 years in service, with average mileages estimated to range from 50 to 100 thousand miles.at these mileages, the subject wheels are likely to have been removed and reinstalled multiple times for various service procedures.odi is concerned about the high wheel separation rates in the my 1997-98 windstar vehicles equipped with aluminum alloy wheels.however, analysis of failure data indicates that most of the incidents in that population of vehicles occur after the vehicles had accumulated 30 thousand miles of service. The factors that increase the risk that inadequate clamp loads may be achieved during service-related wheel installation are not unique to the subject vehicles.testing conducted by ford and vrtc indicate that the my 1998 windstar aluminum wheel fastening system performs similar to the wheel fastening systems on peer minivans.no design or manufacturing defects were identified in the wheel fastening systems of the subject vehicles. Ford will send a mailing to owners of windstar vehicles with aluminum wheels that have high wheel separation rates that reviews the appropriate wheel fastening procedures and states that the wheel nuts should be tightened to the nominal torque, 100 ft-lbs (136 nm), and re-tightened to the same torque after 500 miles.ford?s letter also states that it is ?a good practice to be sure that before installing the wheel the aluminum wheel mounting surface, wheel lug nut area, and the mounting flange are free from dirt, debris, and loose rust to ensure the wheel is seated correctly and the wheel lug nuts remain fully tightened.? Odi will continue to monitor the incidence of wheel fastener failures in the subject vehicle population.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist.the agency will take further action if warranted by the circumstances. For additional information, see the attached closing report.

EA03004

Analysis of odi and ford data has identified 1619 incidents of wheel stud fracture in my 1998 through 2000 ford windstar vehicles, including 69 wheel separations and 11 crashes.ford has not been able to identify any design or manufacturing defects in its analyzis of the problem.ford maintains that the failures are caused by either:(1) inadvertent overtorquing of lug nuts during removal or installation; or (2) fatigue due to insufficient clamp load between the wheel and the brake rotor or drum and hub assembly.according to ford, corrosion, dirt, or damage present on the road wheel at the nut inteface could contribute to the latter condition. Analysis of odi complaint data indicates that the subject vehicles experience wheel stud failures at significantly higher rates than peer minivans.this investigation has been upgraded to further assess the frequency, scope, and trend of the alleged defect condition in my 1997 through 2000 windstar minivans.

PE02085

There is no summary currently available

EA00027

There is no summary currently available

PE00024

This investigation is opened to ascertain facts concerning the problem experience, scope, and rational for issuing a technical service bulletin to correct the problem.historically, previous safety recalls involving similar type of failure have been filed with the agency.

SQ99001

There is no summary currently available

EA98008

There is no summary currently available

PE97048